Interconnecting rigid building components

ABSTRACT

Building constructs for constructing a play structure, a useful construction construct, or the like. In one embodiment, the building constructs are extruded cuboids having notches or other interlocking features. In another embodiment, the building constructs are encased within a polymer shell for enhanced durability or other desirable property. A play structure comprises a plurality of the building elements connected to one another. In one embodiment, the play structure comprises a cabin. Walls of the cabin are constructed by interlocking elongate wall elements. The cabin includes a roof constructed from interlocked flat panels or slats. A roof support elevates the roof over the walls and connects the roof to the walls. A method of constructing a play structure comprises assembling a plurality of the building elements.

BACKGROUND

The present invention generally relates to foam structural buildingcomponents. It relates more particularly to light weight, substantiallyrigid, inter-locking, foam structural units, suitable, though notexclusively, for the creation of toy structures.

There are a plethora of toy construction sets on the market. Many ofthese construction sets utilize building components composed of denseand hard materials, and as such, do not readily lend themselves tocreating resilient structures. Such rigidity can limit the toy-playexperience by the users as well as limit the type of structures able tobe built during the toy-play time. For example, a child creating andusing a child sized raft will likely lead to one or more of the toysbuilding components breaking, possibly because of point load failuresoccurring at the point of connection between the building components.

Further, dense, hard, and rigid building components of such toyconstruction sets are often the cause of injury to children. Forexample, a child falling onto such a building component can cause thechild to receive a painful bruise, cut, or worse. Thus, there is a needfor an improved building component. The present invention addresses thisneed.

SUMMARY

This specification describes technologies relating to a buildingconstruct, often, though not exclusively, implemented as a toy buildingconstruct often as part of a many building construct building kit.Accordingly, this invention provides a building construct, often, thoughnot exclusively, implemented as a toy building construct. The buildingconstruct is unlikely to cause injury when a child falls on, chews on,or throws a building construct. In some implementations, the buildingconstruct primarily has a cuboid shape with a longitudinal axis of 25inches and the two other axes being of an equal length of 2.75 inches,Said implementations also have four cuboid sections removed from thebuilding construct. The four cuboid sections are removed from thebuilding construct such that each end of the building construct has twocuboid sections removed with the two removed cuboid sections opposingeach other. The effect is such that to allow two building constructs tointerlock with each other at a right angle. The depth and width of theremoved sections is such that as to allow three building constructs tojoin at a right angle, two building constructs being parallel to eachother, the third building construct perpendicular to the first two, withthe two parallel building constructs forming a tight seam along theircommon longitudinal axis.

In some implementations, the building constructs are composed of a lightweight and durable material such as a foam material. Examples of suchfoam material include but are not limited to expanded polystyrene,extruded polystyrene foam, or polyethylene foam. Additionally, in someimplementations the building constructs are enclosed within a coveringor shell that imparts a desired characteristic. For example, buildingconstructs can be enclosed within a shell of a high molecular weightpolyethylene (HDPE) providing impact resistance, preventing the enclosedmaterial from being exposed to water and thus prohibiting growth oforganisms, shielding the enclosed material from ultraviolent radiation,enhanced wear and friction resistance, and protection from solvents andfuels. For example, a hollow shell of a building construct can becomposed from HDPE and subsequently filled with extruded polystyrene.

As another example, various water-based adhesives, various phenolics,epoxies, resorcinols, and ureas can be used to coat and encase thebuilding constructions based upon the desired characteristics exhibitedby said coatings. Other coatings and shells are discussed elsewherewithin this document. Some shells, coatings, and even uncovered oruncoated building constructs can also have a portion of the exteriorcoated with various adhesives. For example, such treated buildingconstructs can be used to create structures of greater resilience thanthose composed from untreated building constructs. Further, such treatedbuilding constructs can enable the resulting structures to be weatherand/or water resistant due to the seams between parallel buildingconstructs being sealed as a result of the adhesive. As a non-limitingexample, ethylene acrylic materials or ethylene vinyl acetate (EVA) canbe used as a temporary adhesive.

The details of one or more embodiments of the subject matter describedin this specification are set forth in the accompanying drawings and thedescription below. Other features, aspects, and advantages of thesubject matter will become apparent from the description, the drawings,and the claims.

BRIEF DESCRIPTION OF THE DRAWINGS

Various other objects, features and attendant advantages of the presentinvention will become fully appreciated as the same becomes betterunderstood when considered in conjunction with the accompanyingdrawings, in which like reference characters designate the same orsimilar parts through the several views, and wherein:

FIG. 1 is rendering depicting a three-dimensional side perspective of animplementation of a base building construct.

FIG. 2 is a rendering depicting a top view perspective of animplementation of a base building construct.

FIG. 3 is a rendering depicting a side perspective of a buildingconstruct having adaptations allowing the building construct to have avariable length.

FIG. 4 is a rendering of an implementation of a building constructallowing the joining of two parallel building constructs.

Like reference numbers and designations in the various drawings indicatelike elements.

DETAILED DESCRIPTION

Before the present implementations and systems are disclosed anddescribed, it is to be understood that this invention is not limited tospecific implementations, or to particular compositions, and as suchmay, of course, vary. It is also to be understood that the terminologyused herein is for the purpose of describing particular implementationsonly and is not intended to be limiting.

As used in the specification and the claims, the singular forms “a,”“an” and “the” include plural referents unless the context clearlydictates otherwise. Ranges may be expressed in ways including from“about” one particular value, and/or to “about” another particularvalue. When such a range is expressed, another implementation mayinclude from the one particular value and/or to the other particularvalue. Similarly, when values are expressed as approximations, forexample by use of the antecedent “about,” it will be understood that theparticular value forms another implementation. It will be furtherunderstood that the endpoints of each of the ranges are significant bothin relation to the other endpoint, and independently of the otherendpoint.

“Optional” or “optionally” means that the subsequently described eventor circumstance may or may not occur, and that the description includesinstances where said event or circumstance occurs and instances where itdoes not. Similarly, “typical” or “typically” means that thesubsequently described event or circumstance often though may not occur,and that the description includes instances where said event orcircumstance occurs and instances where it does not.

FIG. 1 is rendering 100 depicting a three-dimensional side perspectiveof an implementation of a building construct 110. In someimplementations, the building construct 110 has a longitudinal axis of alength significantly greater than the other two axes. For example, someimplementations have a longitudinal axis of 25 inches with the otheraxes being equal and of length 2.75 inches. However, it is to beunderstood that the dimensions of a building construct 110 can vary. Thedepicted implementation primarily has a hyperrectangle (a rectangularcuboid or 3-orthotope) shape.

The implementation can be thought of as consisting of three differentsections. The three different sections are, the end sections 120, theinterlock sections 130, and the mid-section 140. The end sections 120can be of varying sizes so long as the end sections 120 do not preventthe mid-sections 140 of parallel building constructs 110, one set on topof the other, from forming a tight seem. For example, in someimplementations, the end sections 120 are of the same two minordimensions as the mid-section 140. In some implementations, the endsections 120 and the cut out sections 130 or apertures 130 are sizedsuch that two parallel and adjacent building constructs 110, interlockedwith a third building construct 110, will form a continuous and tightseam along the seam common to the respective mid-sections 140 of theadjacent and parallel building constructs 110. That is, two buildingconstructs 110 can be joined by interlinking an aperture 130 from eachbuilding construct 110 with said interlink joint having a friction fit.In some implementations, the sides of each building construct are coatedwith a pressure sensitive adhesive, allowing the tight seam to betemporarily glued together.

FIG. 2 is a rendering depicting a top view perspective of animplementation of a base building construct 110. In this depictedimplementation, the cut out sections 130 are shown to be sized such thattwo building constructs 110 can snugly interlink. That is, a cut outsection 130 is sized to tightly engage with a second cut out section130.

In some implementations, the interlinking of two or more buildingconstructs 110 is enhanced through the use of additional fasteners oradhesives. For example, a hook and loop type fastener comprising a firstportion having the loops and attached to an adhesive pad and a secondportion having the hooks and attached to a second adhesive pad can beused to more securely interlink two building constructions 110. That is,the first potion would be attached to the cut out section 130 of thefirst building construct 110. The second portion would be attached to asecond building construct 110. The interlinking of the two buildingconstructs 110 would also allow the hook and loop fasteners to fasten.Alternatively, a contact pressure-sensitive adhesive (“PSA”) can bedistributed into the cut out sections 130 to enable more permanentjoining of two or more building constructs 110.

Similarly, the mid-sections 140 can also be coated with a PSA. Thisenables the tight common seam of two parallel building constructs 110 toadhere to each other. Such bounded building constructs 110 can enablestrong and substantially fluid tight constructions to be created. Forexample, temporary concreate formation and curing guides can beconstructed from such building constructs 110.

Examples of suitable PSAs include, but are not limited to, siliconebased PSAs, including those of a MQ resin nature, acrylic, rubber, epoxybased PSAs, and the like. PSA technologies are well understood withinthe art and will not be further discussed within this application.

In some implementations, the building construct 110 is composed of afoamed polyurethane. For example, in some of such implementations, oneor more building constructs 110 are formed from machining or cutting alarge foam block of polyurethane. Of course, other methods of creationare possible. For example, a polyurethane based building construct 110can also be created through the hold or cold molding of thepolyurethane. Of course other forms of polymers, including polymer foamscan be used to from which to create a building construct 110. Forexample, expanded polystyrene foam and extruded polystyrene foam arealso used in other implementations.

As another example, some implementations are composed frompolypropylene. Most often the implementations are hollow although otherimplementations utilize a polypropylene shell to enclose a polystyrenefoam. For example, such implementations can exhibit resistance to heat,corrosion, chemical leaching and be resilient against physical damage.Additionally, as polypropylene is resistant to fatigue, suchpolypropylene implementations or incased implementations also caninclude a hollowed out area covered by a hinged cover. Typically, thehinged cover is implemented as a living hinge, a hinge implemented via athinner portion of the plastic such as might be implemented in aflip-top bottle lid. Such hollowed out areas can allow the deposit ofsmall items, such as sensors, within the building construct 110.

It will be understood by those skilled the art that other polymers, suchas high-density polyethylene (HDPE), cross-linked polyethylene (PEX),flexible polyvinyl chloride (PVC), nnplasticized polyvinyl chloride(uPVC), and the like can also be used to encase a foamed polymer used tocreate a building construct 110. The choice of which polymer to use canbe made based upon the desired properties of the finished buildingconstruct 110.

If composed from a polymer foam, it is to be understood that the type ofcell structure in a polymer foam used to create a building construct 110will influence its mechanical resilience and flexibility. For example, abuilding construct 110 formed utilizing an open-cell structure foam willlikely exhibit less resilience than that of a close-cell structure foamof the same polymer. However, the same open-cell structure foam willlikely exhibit greater sound absorption.

FIG. 3 is a rendering depicting a side perspective of a buildingconstruct 110 having adaptations allowing the building construct to havea variable length. As shown, in this implementation, the buildingconstruct 110 comprises five sub components; two interlocking sections130, a mid-section 140, two attachment pegs 210. In the depictedimplementation, the attachment peg 210 is four inches long with a radiusof 1 inch, though it should be understood that other dimensions or evenshapes are possible. For example, the attachment pegs 210 could becuboid in shape. It should be understood that while the depictedimplementation utilizes attachment pegs 210, other means of physicalattachment can be used in place of the attachment pegs 210. For example,a compressionable protrusion could extend from an interlocking section130 with the corresponding receptacle of the protrusion being part ofthe mid-section 140. In this way, the exemplary interlocking section 130and mid-section 140 can be attached through simply snapping theprotrusion into the receptacle.

In this implementation, the mid-section 140 has a cylindrical hollowedout portion 220 of approximately the same radius of that of theattachment pegs 210. Similarly, the interlocking sections 130 also havea hollowed out portion, approximately of the same radius but half of thelength of the attachment pegs 210. Some implementations also include aPSA on the attachment pegs 210, allowing for a permanent fixing of aninterlocking section 130 to either a mid-section 140 or anotherinterlocking section 130 by permanently securing the attachment peg intothe hollowed out portion 220 and/or interlocking section 130.

It should be understood that building constructs 110 of varying lengthscan be created by shortening a mid-section 140, or by joining two ormore mid-sections 140 together. In this way, building constructs 110 ofvirtually any length can be created.

FIG. 4 is a rendering of an implementation 310 of a building constructallowing the joining of two parallel building constructs 110. In thisimplementation, two parallel building constructs 110 can be joinedtogether through the use of an interlock block 350. The interlock blocks350 are sized such that approximately half of the interlock block 350fits snugly into an interlock section 130. In some implementations, theinterlock block 350 can be treated with a PSA, and in otherimplementations, the building constructs 110 are also such treated aspreviously noted, allowing the building constructs 110 to be securelyfashioned.

The methods of construction of the building constructs will vary basedupon the chosen material or combination of materials from which thebuilding constructs are made. For example, building constructs can beformed from polystyrene through injection molding, from expandedpolystyrene through utilizing pre-expanded stabilized polystyrene beadsand reheating with steam in a mold and, from extruded polystyrene foamby milling or machining.

While primarily discussed as being implemented in one or more polymers,embodiments of the subject matter and the operations described in thisspecification can be implemented from any suitable material, includingthe substances disclosed in this specification and their structuralequivalents, or in combinations of one or more of them. For example, thedepicted invention could composed from an engineered wood product suchas those incorporating sawdust or sawmill shavings and a syntheticresin.

The building constructs are easily assembled or connected. The buildingconstructs are easily connected by interlocking mating notched portions.Alternatively, parallel building constructs can be assembled through theuse of an interlock block or the like, such as described in FIG. 3. Morepermanent and resilient assemblies can be achieved through the use of aPSA on at least some portion of the building constructs or the interlockblocks, such as the case may be. The manner of connection or assemblyrequires no tools.

It will be understood that the above described arrangements of apparatusand the method therefrom are merely illustrative of applications of theprinciples of this invention and many other embodiments andmodifications may be made without departing from the spirit and scope ofthe invention as defined in the claims.

What is claimed is:
 1. A building kit for making various structures,comprising: a. a set of mid-sections comprising foam hyperrectangles ofpredetermined dimensions such that length of a mid-section is greaterthan both width and depth of the mid-section, each said raid-sectionhaving a uniform hollowed out cylindrical portion spanning the length ofthe mid-section; b. a set of cylindrical shaped pegs of a radius suchthat each peg can be inserted into the hollowed out cylindrical portionof a mid-section and said insertion results in a friction fitrelationship; c. a set of interlock-sections comprising foamhyperrectangles having a width and a depth equal to that of amid-section, each interlock-section shaped on two opposing sides toperpendicularly mate with other interlock-sections, and eachinterlock-section also having a uniform hollowed out cylindrical portionof a radius such that insertion of a peg into the hollowed outcylindrical portion of an interlock-section results in a friction fitrelationship.
 2. A building kit as claimed in claim 1, in which the foamis extruded polystyrene foam.
 3. A building kit as claimed in claim 1,in which the foam is encased within a shell of high molecular weightpolyethylene.
 4. A building kit as claimed in claim 1, furthercomprising: d. A set of interlock blocks, each interlock block sized tofit snugly into an interlock-section such that two interlock-sectionscan attach to the interlock-block.
 5. A building kit as claimed in claim1, wherein each peg is coated with a pressure sensitive adhesive.
 6. Abuilding kit as claimed in claim 4, wherein each interlock block iscoated with a pressure sensitive adhesive.
 7. A building kit as claimedin claim 1, wherein each mid-section's sides are coated with a pressuresensitive adhesive.
 8. A building kit as claimed in claim 1, furthercomprising: d. a set of adhesive backed pads covered by hooks of a hookand loop type fastener; e. a set of adhesive backed pads covered byloops of a hook and loop type fastener.